frequently asked torque specs

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2015 Sportwagen; Golf GLS 2002 (swap from 2L gas); 2016 A3 e-tron
myturbodiesel is pretty reliable, but just to confirm, i looked at my Bentley again just now and indeed - 48ft.lb./65Nm for the 8mm allen-head bolts that attach the carrier to the caliper on the rear brakes of the Mk4.

The bolts that go go into the sliding glide pins are 26ft.lbs/35Nm.
(.pdf of that page)
 
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Van Wylder

Veteran Member
Joined
Jul 8, 2011
Location
SE Ohio
TDI
00 Jetta sedan 5 spd. 03 Jetta wagon 5 spd.
Looking for A3 flywheel bolt torque specs. Installing a Sachs G60/VR6 clutch kit on an ALH, with a 21lb SMF. I know standard ALH torque specs are 44ft lb. + 90 degrees, but I've been told the G60/VR6 kit uses A3 torque specs.

Anybody me know what those specs are? I've looked through here and on the A3 forum and could not find them.
 

Nuje

Top Post Dawg
Joined
Feb 11, 2005
Location
Island near Vancouver
TDI
2015 Sportwagen; Golf GLS 2002 (swap from 2L gas); 2016 A3 e-tron
When I installed the Sachs PD150 clutch/flywheel for my 6-speed 02M transmissions, I just went with the 60Nm+90° that the ALH specs. 200K+ km later, they're still doing just fine.
Can't imagine why/how much difference there'd be with the G60.

(Edit: Visit Mr. Google and enter G60 flywheel torque spec site:tdiclub.com; probably get confirmation there fairly quickly.)
 
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shoebear

Veteran Member
Joined
Aug 1, 2002
Location
Colorado Springs, CO
TDI
1998 Jetta, 2003 Jetta Wagon, 2005 New Beetle, 2013 Sportwagen
Concerning the three horizontal bolts that hold the 02J manual transmission bracket/console/side mount to the transmission case...

Runonbeer has recommended 30 lb-ft +90º twice in this thread (#93 & #131). I trust him, and I'm sure he recommends this from his experience. However, the Jetta Bentley specifies 37 lb-ft (50Nm) +90º at the bottom of page 34-60 under "All Vehicles". This specification is missing from the New Beetle Bentley (I searched and searched).

The bolts are M10x80 with a 16mm shouldered hex head. There is an old (bare) version and a new version with pre-applied blue thread locker. The new part number is N10406204. If you use the old part, you might want to add your own thread locker.

ETKA shows the same part# for all three bolts. The right bolt goes all the way through the mount and protrudes about an inch on the back side. It seems like this should be a shorter bolt, but it isn't.

You can read more details and see photos in these threads:

Hope this is helpful.
 
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Tdi/gti kid

Member
Joined
Nov 4, 2019
Location
Denver Co.
TDI
2011 Jetta Tdi
Torque specifications (Ft-lbs)
ALH engine:
(always replace bolts in bold)
-Drian plug (19mm) 22
-Cam bearing cap (13mm) 15
-Vacuum pump (13mm) 15
-Valve cover (5mm allen) 7
-Cam sprocket (19mm) 33
-T-belt tensioner (13mm) 15
-IP sprocket bolts (13mm) 18
-Pendulum mount to Body mount:(16mm) 30 + 1/4 turn
-Engine mount to engine bracket:(18mm) 44 + 1/4 turn (updated bolts [grey in color] are 74 ft.lbs. trans and engine side)
-Crank shaft bolt: 88 + 90 degrees
-Crankshaft main bearing bolts: 48ft lb + 90 degrees
-Connecting rod bolts: 22 + 1/4 turn (oiled threads and contact surfaces)
-Oil pan bolts (10mm/5mm allen) 11
-Bell housing to oil pan (16mm) 33
-Front seal carrier bolts (10mm/5mm allen) 11
-Rear seal carrier bolts (10mm/5mm allen) 11
-Harmonic balancer bolts (6mm allen) 18 Ft Lb
-Flywheel to crank bolts: 44 + 1/4turn
-Pressure plate to flywheel bolts: 10 ft lb
Loosen and tighten gradually and diagonally (for DMF)

-Bell housing to engine block: 60
-Starter bolts: 50
-Oil filter housing bolts (10mm/5mm allen) 11 + 1/4 turn
-Serpentine belt tensioner (13mm) 18
-Thermostat housing (10mm/5mm allen) 11 don't over do this puppy


-Large timing belt roller:(16mm) 30 + 1/4 turn
-Small upper timing belt roller bolt(13mm) 15
-Small lower timing belt roller nut (13mm) 15
-Intake Manifold to head bolts (6mm allen) 18
-Cylinder head bolts (12mm 12pt.) tighten in the proper sequence to 30, then 44, then 1/4 turn, then 1/4 turn
sequence:

10 4 2 6 8

7 5 1 3 9

-Injection pump to bracket bolts (13mm) 22
-Injector retainers (13mm) 15 ft lbs
-Water pump bolts (10mm/5mm allen) 11
-Engine mount bracket to engine bolts (16mm) 33
-rivnuts (17mm) 30
-Wheel Lugs (17mm) 89
-Glow Plugs (10mm) 11
-Transmission mount to "bracket that holds transmission" (the 2 big 18mm bolts that hang the tranny from the mount) - 100nm (74ftlbs)

-Dog bone (aka) Rear Transmission Mount (aka) Pendulum Support...

-Rear 2 bolts (to subframe) 20nm + 90deg (15ftlbs + 1/4turn)
-Front 2 (to tranny) 40nm + 90deg (30ftlbs + 1/4turn)


-Drive Shaft to tranny - 40 Nm (30 ft lb)
(According to Bentley, it's done in 2 stages... first tighten them diagonally to 10 NM (7.4 Ft*Lbs), then tighten them diagonally to 40 NM (29.5 Ft*Lbs) (that is: if those are 8 mm bolts... the 10 mm bolt cars are tightened to 70 NM --ymz)

-transmission (manual) drain/fill plugs 18 ftlb.
-C.V. axle: M8-30ft.lb, M10-59ft.lb
-Tie rod end nut 33 ft lb, confirmed
-Tie rod end to tie rod 37 ft lb

Ball joint to spindle (self-locking nut): 45 Nm

Ball joint to control arm (use new bolts): 20 Nm plus an additional 90* turn

Sway bar end link at control arm: 33ft lb

Strut retainer bolt and self-locking nut (bolt that goes through spindle, holding the strut in place; replace hex bolt. Bolt point must point to the front of vehicle): 60 Nm plus an additional 90* turn; Never less than 90*

Rear, upper shock mount: 30Nm (22ft -lb.) + 1/4 turn (90 degrees)

Caliper to carrier (8mm allen; caliper->carrier pins): 28 Nm

Carrier to spindle("ribbed combi bolts"): 125 Nm

Brake hose to caliper(banjo union and bolt): 35 Nm

Tie rod end self-locking nut: 45 Nm
Do a lot of these Torque specs apply to 2.0L TDI Cjaa? If not trying to find bell housing to engine and few other torque specs. Found most of them!
 

PakProtector

Veteran Member
Joined
Jan 5, 2014
Location
AnnArbor, MI
TDI
Mk.4's and the Cummins
Concerning the three horizontal bolts that hold the 02J manual transmission bracket/console/side mount to the transmission case...

Runonbeer has recommended 30 lb-ft +90º twice in this thread (#93 & #131). I trust him, and I'm sure he recommends this from his experience. However, the Jetta Bentley specifies 37 lb-ft (50Nm) +90º at the bottom of page 34-60 under "All Vehicles". This specification is missing from the New Beetle Bentley (I searched and searched).

The bolts are M10x80 with a 16mm shouldered hex head. There is an old (bare) version and a new version with pre-applied blue thread locker. The new part number is N10406204. If you use the old part, you might want to add your own thread locker.

ETKA shows the same part# for all three bolts. The right bolt goes all the way through the mount and protrudes about an inch on the back side. It seems like this should be a shorter bolt, but it isn't.

You can read more details and see photos in these threads:

Hope this is helpful.
It is quite easy to tear the heads from those bolts if they are the ones with OE locker. They come out easily if you heat them up. Unfortunately I learned this after tearing the heads off, drilling enough of the remainder low enough to slip the mount off). Solved it on the ground with a torch and vise grip on the stub.

Douglas
 
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